LAUSR

Fused filament fabrication (FFF) has been widely adopted due to its simplicity and cost‐effectiveness. But until now, its application materials are still limited. Polyolefin material is one of the most commonly used plastics. However, low‐density polyethylene (LDPE) is rarely used in FFF due to the inadequate strength of the filaments and the warpage of the printed parts. In this work, polystyrene (PS) is added to LDPE to obtain blend filaments. After that, the filaments are used to validate the possibility of in situ microfibrillation directly in the process. The results show that the addition of PS can significantly improve the bending strength, bending modulus, and hardness without affecting the heat resistance and crystal transition of the composite. Besides, the PS dispersed phase can form microfibers under the influence of the shear field. The formation of microfibers can significantly enhance the mechanical properties of composites. The tensile strength and Young's modulus increase by 140% and 221%, respectively. The warping deformation and surface morphology of printed parts are also improved. This study provides a new idea for utilizing low‐strength polyolefin in 3D printing and achieving performance enhancement.